Method of Using Conductive Elastomer for Electrical Contacts in an Assembly

ABSTRACT

A manufacturing method for manufacturing an electronic device is disclosed. Conductive elastomers comprising of various configurations and resistivity are coupled to contact pads of an electronic device. The conductive elastomers are also coupled to substrate contacts on a substrate, allowing the conductive elastomers to function as electrical connection from device to substrate as well as to embed one or more passive components at the contact pads of the electronic device.

RELATED APPLICATIONS

This application claims priority, under 35 U.S.C. §119(e), from U.S.provisional application No. 61/244,861, filed on Sep. 22, 2009, which isincorporated by reference herein in its entirety.

FIELD OF THE INVENTION

This invention relates generally to the manufacture of electroniccomponents, and more particularly to using a conductive elastomer toembed one or more passive components in an electronic device assembly.

BACKGROUND OF THE INVENTION

Conventional uses of electrically conductive elastomers in electronicdevices rely on the high conductivity and elastic nature of conductiveelastomers to implement interface contacts or interconnection. Forexample, conductive elastomers are used at interface contacts to makemulti-contact connectors, as conductive interposer in array package,directly as discrete molded conductive plastic passive components, or aselectrical interconnections and contacts of electronic devices.

SUMMARY OF THE INVENTION

The present invention generally relates to a method for assembling anelectronic device. An electronic device or substrate comprising aplurality of contact regions is manufactured. Conductive elastomershaving different resisitivities are coupled to contact pads. By choosinga set of noble configurations and/or structures for contact padsimplemented by the conductive elastomers at an electronic device orsubstrate and at a target platform to which an electronic device orsubstrate is attached, the passive components used for operation ofelectronic device or substrate may be directly embedded at the contactpads, providing substantial advantages over using a highly conductiveelastomer material simply as an interconnection or as an interfacecontact. Embedding structures at a contact pad using conductiveelastomers with different resistivities allows substantial reduction ofthe area overhead occupied by passive components on a target platform,such as a printed circuit board (PCB), which are essential to complementthe normal operation of an electronic device on a target platform.Additionally, embedding structures in a contact pad using conductiveelastomers beneficially enables solderless assembly of electronicproducts while reducing manufacturing costs by reducing the mounting ofpassive components and the thermal reflow process. Thus, in contrast toconventional use of conductive elastomers for their high conductivity,the current invention uses conductive elastomers having differentresistivities, including an insulating elastomer, as contact padmaterials so that a discrete or a set of passive components are embeddedat contact pad of an electronic device or package for solderlessassembly of electronic components.

The features and advantages described in the specification are not allinclusive and, in particular, many additional features and advantageswill be apparent to one of ordinary skill in the art in view of thedrawings, specification, and claims. Moreover, it should be noted thatthe language used in the specification has been principally selected forreadability and instructional purposes, and may not have been selectedto delineate or circumscribe the inventive subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an example of a substrate including contact pads coupled toconductive elastomers according to an embodiment of the presentinvention.

FIG. 2 illustrates example connections of resistors to an electroniccomponent.

FIG. 3 is a side-view of example couplings of conductive elastomers tocontact pads to implement resistors according to embodiments of thepresent invention.

FIG. 4 illustrates example connections of capacitors to an electroniccomponent.

FIG. 5 is a side-view of example couplings of conductive elastomers tocontact pads to implement capacitors according to embodiments of thepresent invention.

FIG. 6 illustrates cross-sectional views of examples of combinations ofpassive components implemented by coupling conductive elastomers tocontact pads of a substrate according to embodiments of the presentinvention.

FIG. 7 illustrates cross-sectional views of additional examplecombinations of passive components implemented by coupling conductiveelastomers to contact pads of a substrate according to embodiments ofthe present invention.

FIG. 8 shows cross-sectional views of various combinations of resistorsand capacitors implemented by coupling conductive elastomers to contactpads of a substrate according to embodiments of the present invention.

The Figures depict various embodiments of the present invention forpurposes of illustration only. One skilled in the art will readilyrecognize from the following discussion that alternative embodiments ofthe structures and methods illustrated herein may be employed withoutdeparting from the principles of the invention described herein.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention are now described with reference tothe Figures where like reference numbers indicate identical orfunctionally similar elements. Also in the Figures, the left most digitsof each reference number correspond to the Figure in which the referencenumber is first used.

Reference in the specification to “one embodiment” or to “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiments is included in at least oneembodiment of the invention. The appearances of the phrase “in oneembodiment” or “an embodiment” in various places in the specificationare not necessarily all referring to the same embodiment.

Additionally, the language used in the specification has beenprincipally selected for readability and instructional purposes, and maynot have been selected to delineate or circumscribe the inventivesubject matter. Accordingly, the disclosure of the present invention isintended to be illustrative, but not limiting, of the scope of theinvention, which is set forth in the claims.

FIG. 1 is an example of a substrate 100 including contact pads 110, 120coupled to conductive elastomers. In various embodiments, the substrate100 comprises an integrated circuit die, a stacked integrated circuitdie, a packaged integrated circuit component, a component, a flex, arigid flex, a printed circuit board (PCB) or similar entity. In variousembodiments, the conductive elastomers have different resistances,configurations and/or geometries. For example, the contact pad 110, 120may be a simple, uniform pad, or may be a pad having a structureincluding more than one elastomer material for implementing differentfunctions such as an orientation indicator, a thermal dissipater, amechanical support, a power connection, a ground connection, a passivecomponent, a combination of passive components or other suitablefunction. Different conductive elastomers may have differentconductivities, which range from less than 10⁻¹⁰ siemens/cm for aninsulating material, to 10⁻⁵ siemens/cm for a semiconducting materialand up to 10⁵ siemens/cm for a conducting material. The variation inconductivity allows different conductive elastomers to operate as aninsulator, a semiconductor or a metal. In one embodiment, a contact pad110, 120 is coupled to a conductive elastomer having a uniformconductivity. Different conductivities may be chosen for differentcontact pads. Alternatively, the contact pad 110, 120 is coupled to oneor more conductive elastomers.

In one embodiment, a contact pad 110, 120 having a uniform zero ohmresistance elastomer is used as an interconnection pad. Alternatively, acontact pad 110, 120 having a uniform non-zero resistance is used as aninterconnection pad coupled to a built-in resistor. Or, a contact pad110, 120 having an insulating elastomer is used as an interconnect padcoupled to an embedded capacitor. Or more elastomers are used at aninterconnection pad to embed a combination of a resistor and a capacitorat contact pad 110, 120.

In one embodiment, a conductive elastomer is coupled to a contact pad110, 120 using in-situ lamination, deposition, evaporation, injection,bonding or any other suitable method. Additionally, the conductiveelastomer has a geometry and/or size that varies depending in part onthe functional requirements of a particular application. Coupling thecontact pad 110, 120 to one or more different conductive elastomersallows the contact pad 110, 120 to implement different types ofconnections, such as a simple interconnect, connections to a resistor,to a capacitor, to a combination of a resistor and a capacitor, to aninsulator or to one or more other passive components.

In various circuit implementations, a pull-up or pull-down resistor isconnected to an input pin of an electronic device to configure anoperation mode of the electronic device. In other circuitconfigurations, such as a serial termination resistor is inserted into asignal path next to an output driver of an electronic device to reduceringing noise by modifying the impedance of a signal trace coupled tothe electronic device. In additional circuit implementations, anexternal resistor is coupled to a driver of an electronic device toregulate the driver's current output. For example, an external resistoris used to control the current output from a programmable input/output(PIO) pin of an electronic device to control the brightness of a lightemitting diode (LED).

FIG. 2 illustrates example connections of resistors to an electronicdevice 200. For purposes of illustration, FIG. 2 illustrates anelectronic device 200 having four pins, with a resistor coupled to eachpin. In the example of FIG. 2, resistor R1 is used as a mode selectresistor to couple a first pin of the electronic device 200 to ground,which determines whether the electronic device 200 operates in a normalmode or in a test mode. Resistor R2 is used as a signal terminationresistor coupled to a second pin of the electronic device 200. ResistorR3 operates as a pull-up resistor coupled to pin 3 of the electronicdevice 200 and to a voltage source, for example, to disable anactive-low write protect function for the electronic device 200. Alsoshown in FIG. 2, resistor R4 is coupled to pin 4 of the electronicdevice 200 as a current limiting resistor controlling the currentflowing to a light emitting diode (LED) 210.

In the configurations shown by FIG. 2, resistor R1 and resistor R3generally have a high resistance, such as in the order of 10 kΩ. Theresistance of resistor R4 varies from several hundred ohms to onethousand ohms to control the brightness of LED 210. Because resistor R2is used as a signal termination resistor, a more precise resistancearound tens of ohms is typical.

In one embodiment, the resistors R1, R2, R3, R4 shown in FIG. 2 areimplemented by coupling one or more conductive elastomers havingdifferent resistances to each contact pad of the electronic device 200.Coupling a conductive elastomer of different resistance to a contact padallows the contact pad to function as an electrical connection with apassive component embedded at the contact pad. To implement differentresistors for different applications, the resistance of the conductiveelastomer coupled to the pad is varied. The conductive elastomer enablescoupling of a resistor to a contact pad without the need to solder aseparate external resistor on PCB or target platform to couple thefunctionality of a pin in the electronic device 200, conserving area ona PCB or target platform including the electronic device 200.

In various embodiments, the cross-sectional geometry of a contact padcoupled to one or more conductive elastomers is fabricated in a shape,such as a cylindrical cross-section, a cubic cross-section, a rhomboidalcross-section, an octagonal cross-section or any other suitablecross-sectional geometry. To modify the resistance of a conductiveelastomer coupled to a contact pad, the resistivity or thecross-sectional area of conductive elastomer is varied. For example, ifa conductive elastomer has uniform cross section area A and resistivityρ, then the resistance R of conductive elastomer is shown as R=ρ(L/A),where L denotes the height or the length of conductive elastomer and Adenotes its cross-sectional area. By choosing a proper resistivity ρ, aparticular resistance can be fabricated for a conductive elastomer withpredetermined height and cross-sectional area.

Various methods are applicable to couple conductive elastomer to acontact pad. For example, a conductive elastomer having a specificresistance can be directly applied for in-situ IC contact padfabrication as the number of resistors needed to complement thefunctionalities of I/O pins in an IC device is not very many.

However, coupling conductive elastomers to the contact pads of a printedcircuit board (PCB) or a system board, where a large number of resistorscould be needed, then a noble approach is required, if assuming only alimited number of conductive elastomers are available for couplingresistance to contact pads. One approach is to vary the cross-sectionareas of conductive elastomers at different contact pads, but thecross-section area would be the same within a contact pad. Anotherapproach is to stack multiple conductive elastomers of differentresistivity at a contact pad with a height properly selected for eachcomprising conductive elastomer. One embodiment is to stack multipleconductive elastomers of different resistivity at a contact pad to comeout a stack of conductive elastomers having a net height the same amongall contact pads in a PCB or a system board and has a total resistancematching a target value required by an IC pin. For example, assuming alimited set of conductive elastomers is used for fabricating contactpads at a PCB, where one conductive elastomer has a resistivity ofapproximately zero ohm-cm, one has a resistivity of approximately onehundred ohm-cms, one has a resistivity of approximately one thousandohm-cms, one has a resistivity of approximately ten thousand ohm-cms,and the last one has a resistivity large enough to act as an insulator,it is possible to selectively couple these comprising conductiveelastomers at a contact pad to come out a net resistance value matchingthe functional requirements of I/O pins by properly choosing the heightof each comprising conductive elastomer under a specific cross section.

FIG. 3 is a side-view of example couplings of conductive elastomerscoupled to contact pads for implementing resistors. The examplecouplings of conductive elastomers depicted by FIG. 3 illustrateexamples of obtaining various resistances using conductive elastomers.For purposes of illustration, FIG. 3 depicts four cylindrical contactpads 310, 311, 312, 313. The contact pads 310, 311, 312, 313 are coupledto a surface of a substrate 300 at substrate contacts, 320, 321, 322,323, respectively. The contact pads 310, 311, 312, 313 are also coupledto target contacts 390, 391, 392, 393, respectively, on a targetplatform 395 of an electronic assembly. The dimensions of the substratecontacts 310, 311, 312, 313 and/or the target contacts 390, 391, 392,393 may differ from the cross section of the contact pads 310, 311, 312,313 so long as the size difference does not cause spurious effect. Forexample, the substrate contacts 320,321,322,323 may have across-sectional area that is larger or smaller than the cross-sectionalarea of the contact pads 310, 311, 312, 313.

If using the cross-sectional area of contact pad 310 as a reference,reducing the cross-sectional area increases the resistance. For example,if the cross-sectional area of contact pad 311 is one-third of thecross-sectional area of contact pad 310, then the contact pad 311 wouldhave a resistance three times of the resistance of contact pad 310, ifthe same conductive elastomers are used for both contact pad 310 andcontact pad 311. In one embodiment, an insulating elastomer 312B iscoupled to a conductive elastomer 312A to provide mechanical supportwithout altering the resistance, as shown by contact pad 312.

In the example of FIG. 3, contact pad 313 comprises a multi-layerconductive elastomer having a resistive section 325 coupled to aconducting section 326. Coupling the resistive section 325 to theconductive section 326 lowers the height of the resistive section toreduce the resistance of contact pad 313 proportionally relative to acontact pad having a similar cross-sectional area and a full height ofresistive section, such as a contact pad 310. While FIG. 3 shows theconducting section 326 coupled to a first side of the resistive section325, in another embodiment the conducting section 326 is coupled to asecond side of the resistive section 325. Alternatively, the conductingsection 326 is divided into a first conducting subsection and a secondconducting subsection with the first conducting subsection coupled to afirst side of the resistive section 325 and the second conductingsubsection coupled to a second side of the resistive section 325. Theresistive section 325 may be divided into a first resistive subsectionand a second resistive subsection having a different resistivity thanthe first resistive subsection and either the first resistive subsectionor the second resistive subsection may be coupled to either the firstconductive subsection or to the second conductive subsection in multipleconfigurations.

In circuit implementations, a capacitor is frequently coupled to a powerpin of electronic device to filter out power noise and to provideelectronic charges during circuit switching. Additionally, a capacitormay be connected to a pin of electronic device for use in pincapacitance load compensation, as a coupling capacitance to an internalcircuit of electronic device, as a conversion device connected to apulse width modulation (PWM) output, or for use to block a directcurrent (DC) output at pin, to adjust circuit timing and/or a variety ofother functions. FIG. 4 illustrates example connections of capacitors toan electronic device 410. In the example of FIG. 4, capacitor C1operates as a decoupling capacitor coupled to pin 1 VCC of theelectronic device 410 as well as to ground and a power source. CapacitorC2 is a load capacitor coupled to ground and to pin 2 of the electronicdevice 410. Capacitor C3 in FIG. 4 operates as a blocking capacitorcoupled in series to pin 3, which is a PWM output of the electronicdevice 410. Capacitor C4 is coupled to pin 4 of the electronic device410 and to ground for use in a timing adjustment capacitor, such as theone used in a PLL feedback circuit. Typically, power decouplingcapacitor C1 may tolerate a higher variation in capacitance value, whileother capacitors, such as C2, C3, C4 shown in FIG. 4, may require a moreprecise control in capacitance value, depending upon the applicationsfor which they are used.

In one embodiment, a non-conducting elastomer or insulating elastomercoupled to a contact pad constructs an embedded capacitor at contactpad. The non-conducting elastomer coupled and sandwiched between twocontact pads, where one is at substrate and the other is at targetplatform, creates a parallel plate capacitor. The capacitance C of aparallel plate capacitor with a uniform insulating dielectric materialis shown as ∈A/D, where ∈ is the dielectric constant of insulatingconductive elastomer, A is the area of parallel plates and D is thedistance between two parallel plates. Inserting an insulating elastomeror insulating material between two parallel plates raises the dielectricconstant between them to increase the capacitance of a parallel platecapacitance.

FIG. 5 is a set of side-view examples of fabricating embedded capacitorat contact pads. Three embedded capacitors 510, 511, 512 shown in FIG. 5have a first surface coupled to a substrate 500 at substrate contacts orpad contacts 520, 521, 522 respectively and a second surface coupled totarget contacts 590, 591, and 592 on a target platform 595 respectively.

Similar to the resistance embedded at a contact pad described above inconjunction with FIGS. 2 and 3, the capacitance embedded at a contactpad 510, 511, 512 may be modified. For example, enlarging or reducingsurface area of a substrate contact 520, 521, 522 and/or surface area ofa target contact 590, 591, 592 could adjust the capacitance embedded ata contact pad 510, 511, 512, even though the physical dimension ofcontact pad 510, 511, 512 is kept unchanged. Unlike the resistanceembedded at contact pads 310, 311, 312, 313 described above inconjunction with FIG. 3, enlarging the cross section area of contact pad510, 511, 512 has little impact on changing the value of embeddedcapacitance if the surface area of substrate contact 520, 521, 522and/or the surface area of target contact 590, 591, 592 are keptunchanged.

In one embodiment, the capacitance of a contact pad 512 is increased byreducing the height of insulating elastomer. As shown in FIG. 5, acontact pad 512 comprises an insulating section 525 coupled to aconducting section 526. To maintain a uniform height for contact pad512, the reduction in height of insulating layer 525 is allocated tothat of conducting layer 526 accordingly. In an alternative embodiment,the conducting section 526 is divided into a first subsection and asecond subsection where the first subsection is coupled to a firstsurface of the insulating section 525 and the second subsection iscoupled to a second surface of the insulating section 525, so that theinsulating section 525 is positioned between two conducting subsections.By coupling an insulating section 525 to a conducting section 526, thecapacitance of the contact pad 512 is adjustable while the height ofcontact pad still remains constant.

In an embodiment where a small capacitance is required, a small embeddedcapacitor is constructed by having a substrate contact 520 directlycoupled to a target contact 590 but without insulating material inbetween. Or an insulating material can be applied to surround or beyondthe pad contact 520 and/or the target contact 590 simply as a mechanicalsupport. In summary, the dimension of comprising insulating elastomer ischangeable with negligible impact on the precision of capacitanceembedded at contact pad 510, 511, 512, if the cross-sectional area ofinsulating elastomer is large enough to cover the area of pad contact orsubstrate contact 520, 521, 522 and the area of target contact 590, 591,592 to which the contact pad 510, 511, 512 is attached. By altering thearea of substrate contact 520, 521, 522, the area of target contact 590,591, 592, and/or the thickness of insulating layer between the substratecontact 520, 521, 522 and the target contact 590, 591, 592, thecapacitance of a contact pad is modified.

FIG. 6 illustrates cross-sectional views of examples of combinations ofpassive components implemented by coupling multiple conductiveelastomers, or “combo elastomers”, to contact pads of a substrate. The“combo elastomers” permit construction of a contact pad including anembedded capacitor as well as an embedded electrical conduction pathconnecting a target contact to pad contact. In the examples shown byFIG. 6, some contact pads have a similar structure to the contact padsincluding embedded resistors shown in FIG. 3. However, the use ofmultiple elastomers each having different resistivity and differentconnections at substrate contacts and target contacts when constructingthe contact pads causes the combo elastomer to provide differentfunctionalities. Additionally, the examples shown in FIG. 6 are examplesof contact pads having a split pad design.

In FIG. 6, two example structures of combo elastomers 610, 611 areillustrated. For purposes of illustration, the example combo elastomers610, 611 have a cylindrical structure, although in other embodiments thecombo elastomers 610, 611 may have different structures, such as havinga cross section of triangular, square, rectangular, rhomboidal,hexagonal, octagonal or other shape. Additionally, in variousembodiments the combo elastomers 610, 611 have different profiles, suchas a square profile, a rectangular profile, a trapezoidal profile, athin flat plate or any other suitable profile.

The combo elastomer 610 comprises a conductive core 613, a conductingcircular ring 615, and an insulating elastomer layer 614 sandwichedbetween the conductive core 613 and the conducting circular ring 615. Inan alternate embodiment, an additional layer of insulating elastomer isaffixed to the outer sidewall of the conducting circular ring 615,provided that the additional layer of insulating elastomer does notcause spurious capacitance. In one embodiment, the insulating elastomeraffixed to the outer sidewall of the conducting circular ring protectsthe conducting circular ring 615. The combo elastomer 611, comprises aconductive core 618 and an insulating elastomer 619 substantiallysurrounding the outer sidewall of conducting core 618.

For applying combo elastomer 610, a target contact pad comprising aninner conducting contact 690 and a surrounding circular conductingcontact ring 691 with an insulation gap in between is included in atarget platform 695. The inner conducting contact 690 couples to theconductive core 613 of the combo elastomer 610 while the circularconducting contact ring 691 couples to the conducting ring 615 of thecombo elastomer 610. At the surface of substrate 600, there is asubstrate contact 620 coupling to the conductive core 613 of comboelastomer 610. In an embodiment, at the surface of substrate 600 thereis an outer conducting contact 621 circulating the substrate contact620, for coupling to the conducting ring 615 of the combo elastomer 610and in turn coupling to the circular contact ring 619 at the targetplatform 695.

In one embodiment, to construct a decoupling capacitor embedded at powerpin of an electronic device, a configuration similar to combo elastomer610 is applicable. It comprises an inner conductive core 613 forconnecting an external power to a pad contact 620 of the electronicdevice and a grounded conductive ring 615 surrounding the innerconductive core 613 over an insulation layer 614 to implement anembedded capacitor 612 at contact pad. A small resistive or a highlyconductive elastomer may be chosen for the conductive core 613,depending upon the requirement in power noise filtering.

Using combo elastomer 610 as a contact pad of an electronic device, theinner conductive core 613 connects a power or signal from a conductingcontact 690 at a surface of target platform 695 to a pad contact (i.e.substrate contact) 620 at substrate. The conductive core 613 and theconductive ring 615 of combo elastomer 610 form two surfaces of acylindrical capacitor 612 embedded at the contact pad, including aninsulation elastomer 614 as a dielectric layer of the capacitor 612.Modifying the thickness of insulation elastomer 614 alters thecapacitance of combo elastomer 610.

If conductive core 613 is composed of an elastomer material with acontrolled resistivity, the combo elastomer 610 becomes a distributedresistor-capacitor (RC) circuit, which may function as a low pass filterdirectly embedded at contact pad. In an embodiment, a conductive padcontact ring 621 is incorporated at the surface of substrate 600 toprovide an additional ground connection from target platform tosubstrate for the combo elastomer 610.

In an embodiment, another configuration of combo elastomer 611 is shownin FIG. 6, which couples a conductive path and an embedded capacitor toa contact pad. In the configuration, the surface of target platform 695includes a set of target contacts, which comprises a conducting contactcore 692, surrounded by an insulation gap and further surrounded by aconducting contact ring 693. The combo elastomer 611 at contact padcomprises a conductive core 618 surrounded by an insulating cylindricalelastomer 619, although in alternative configurations the conductivecore 618 and the insulating cylinder 619 may have a differentcross-sectional geometry. At the surface of substrate 600, a substratecontact or pad contact 622 is sized to have a cross-sectional area atleast partially overlapping with the target contact ring 693 being tiedto ground.

Applying combo elastomer 611 as a contact pad of an electronic device,the conductive core 618 couples the conducting target contact 692 at thesurface of target platform 695 to the pad contact 622 at the surface ofsubstrate 600 for connecting power or signal from target platform tosubstrate. Meanwhile, the pad contact 622 on substrate is in contactwith the conductive core 618 to function as an electrode of two embeddedcapacitors 616, 617, which is coupled to the target contact ring 693functioning as the opposite electrode. The insulating elastomer 619 actsas a dielectric layer. The area overlapping between the pad contact 622and the target contact ring 693 determines the capacitance value ofembedded capacitor 617. The capacitance value is adjustable by changingthe size of pad contact 622 and the dimension of target contact ring693, provided that the conductive core 618 is not in contact with theouter target contact ring 693 to short both. In various embodiments, thethickness of combo elastomer 611 as contact pads for an IC package, PCB,or substrate, is in millimeter or sub-millimeter range. In otherembodiment, such as in integrated circuit applications, the thickness ofcombo elastomer 611 is in thinner micrometers or sub-micrometer range.

If the conductive core 618 in combo elastomer 611 is constructed byusing a resistive elastomer, a resistive core is formed. The comboelastomer 611 then functions as a resistor connected to a contact padwith companion capacitors 616, 617 embedded at the contact pad. Thus,depending on the configuration of substrate contacts and target contactsin an electronic assembly and the conducting properties of elastomermaterial comprising a combo elastomer, the combo elastomer may functionas an embedded resistor, an embedded capacitor, a substrate mechanicalsupport or as other desirable functions.

FIG. 7 illustrates cross-sectional views of additional example comboelastomers. One embodiment is the coupling of elastomers from aplurality of contact pads form a different type of combo elastomer. Forexample, in FIG. 7 two elastomers at two contact pads are coupled toform a combo elastomer, where a first elastomer 710, such as aconducting elastomer, is coupled to a second elastomer 711, such as aninsulating elastomer, by connecting their respective pad contacts orsubstrate contacts 720 and 721 together. Connecting the respective padcontacts can take place at the surface of substrate or through an innerlayer of substrate. In dual pad configuration, the first elastomer 710couples a first target contact 790 at the surface of target platform 799to a first pad contact 720 at the surface of substrate 700 to connectsignal or power from target platform to substrate. The second elastomer711 couples a second target contact 791, which is grounded at thesurface of target platform 799, to a second pad contact 721 at thesurface of substrate 700 to form a capacitor embedded at pad contact721. Connecting pad contacts 720 and 721 at the surface of substrate 700forms a combo elastomer that enables the connection of power or signalfrom target platform to substrate with an embedded capacitor connectedto contact pad.

In alternative configurations, FIG. 7 shows two other example comboelastomers 712, 715 formed by having two different elastomers buttedwithin a single contact pad. The combo elastomer 712 comprises a firstelastomer 713, such as a conducting elastomer, and a second elastomer714, such as an insulating elastomer, each in a column structure, suchas a half cylindrical column, a rectangular column or in column of othergeometric shape. In one embodiment, split contacts are applied to comboelastomer 712,715, either at the surface of substrate 700 or at thesurface of target platform 799. Signal or power could be transferred byusing a smaller half of combo elastomer 712,715, such as the conductingelastomer 713, 716, while the embedded capacitor could use a larger halfof combo elastomer, such as the insulating elastomer 714, 717 shown inFIG. 7. The pad contact or target contact could be asymmetrical andcomprises two unequal contact sizes at a single contact pad.

As shown in the examples of FIG. 7, target contacts at the surface oftarget platform 799 comprise a first contact region 792, 794 coupled tothe first conducting elastomer 713, 716 and a second contact region 793,795 coupled to the second elastomer 714, 717 for combo elastomer 712,715. Additionally, the example combo elastomers 712, 715 are coupled toa pad contact 722, 723 included at the surface of substrate 700. Inanother embodiment, the pad contact included at the surface of substrate700 comprises a first contact region and a second contact region.

Many digital designs include circuits having a combination of a resistorand a capacitor (an “RC circuit”). FIG. 8 shows examples of RC circuitsconnected to pins 1-5 of an example integrated circuit (IC) 800. An RCcircuit can be embedded at a contact pad of IC 800 with proper couplingof one or more conductive elastomers at respective pin.

In the example RC circuits depicted by FIG. 8, an RC circuit coupled topin 1, 2 or 3 of the IC 800 is implemented by a combo elastomercomprising a resistive conducting elastomer core surrounded by aninsulating elastomer. By varying the configuration and signal connectionof the pad contacts 811, 812, 813 at a substrate and/or by varying theconfiguration and signal connection of the target contacts 821,822,823at a target platform, different RC circuits, such as the RC circuitsconnected to pins 1, 2 and 3 of IC 800, can be implemented by using asimilar combo elastomer that has a resistive conducting elastomersurrounded by an insulating elastomer. The pin connection, outputsignal, ground connection and the structure of combo elastomer for theembedded RC circuits coupled to pins 1, 2 and 3 in FIG. 8 are shown forpurposes of illustrations.

FIG. 8 also shows examples of additional RC circuits coupled to pins 4and 5 of the IC 800, whose combo elastomer has a different structurethan the combo elastomer used in the implementation of RC circuitscoupled to pins 1, 2 and 3. For example, the RC circuit embedded incombo elastomer 840 coupled to pin 4 of the IC 800 comprises a resistivecore, surrounded by an insulating elastomer, which is further surroundedby an outer conduction elastomer. Additionally, the pad contact and thetarget contact coupled to the combo elastomer 840 differ in contactsize, with the pad contact being the pin 4 of IC 800 and the targetcontact being the RC circuit output connected to target platform. Comboelastomer 850 shown in FIG. 8 is an alternative implementation of sameRC circuit coupled to pin 4 of IC 800, where pad contact and targetcontact are similar in the contact size. The RC circuit coupled to pin 4could be used in a pulse width modulation (PWM) or loop filter circuit,and so on.

The combo elastomer 860 in FIG. 8 depicts an example implementation ofanother RC circuit coupled to pin 5 of IC 800. It includes an additionalpower connection to a RC circuit. In one embodiment, combo elastomer 860is formed by linking elastomers at two contact pads, where one padcontact at the surface of substrate functions as pin 5 of IC 800 and theother functions as a VCC connection; furthermore, two target contactsconnected at the surface of target platform function as the RC circuitoutput through the combo elastomer 860. Thus, using conductiveelastomers with controlled resistivity and structuring conductiveelastomers in various geometries allow passive components and theircombinations being embedded at a contact pad.

Using elastomer with passive components embedded at contact pad, asdescribed above, is a valuable approach to solve problems encountered intraditional electronic product assembly. Traditional electronic productassembly requires to surface mount a large number of passive componentson PCB, which tends to extend the size of PCB in order to accommodatethe supportive passives in an electronic assembly. Many of these passivecomponents are decoupling capacitors, compensation capacitors,termination resistors and/or current limiting resistors. By usingconductive elastomers with controlled resistivity and structure, many ofthe passive components can be directly embedded at the contact pads ofan integrated circuit (IC) during the contact pad fabrication. Thus, thesurface area used by discrete passive components on a PCB or targetplatform could be substantially reduced. It also eliminates theplacement step of passive components in conventional electronicassembly, which is a timely process especially if the quantity ofpassive components to be placed is huge.

Furthermore, embedding passive components at the contact pads of anintegrated circuit (IC) device, the excessive routing traces on PCB forconnecting external discrete passives to pins are eliminated to lowerthe spurious signal noises and interferences for a more robustperformance of an electronic system.

Additionally, after components are soldered on a PCB or target platform,to de-solder a defective IC and to replace a new component at rework isalso a challenging task, especially if the pin pitch and the pad size ofcomponent is small. The difficulty in removing the components from anelectronic assembly and the risk of damaging a component duringcomponent removal limit the reuse of components within the electronicassembly or system. A cold assembly process, such as the use ofconductive elastomers described above, simplifies manufacturing processand favors component reuse to lower product cost and to reduceelectronic wastes which is highly desirable for green environments.Embedding passive components in contact pads using conductive elastomerscould cut down the use of trillions discrete passive components annuallyand simplify material management. Using elastomer as contact padmaterial for electronic device would make a solderless electronicassembly feasible as conductive elastomer could make a good contact withtarget contacts on a PCB or target platform.

For surface mount technology, there is an emerging challenge to solderultra-small passives with enough soldering but without suffering solderbridging in an electronic assembly. Embedding passive components atcontact pad mitigates the difficulty of soldering ultra-small passivecomponents to an electronic assembly. As portable electronic productsbecome more popular, the active and passive components assembled in anelectronic product become smaller and smaller. For example, a 0603package size having a dimension of 60 mils in length and 30 mils inwidth was commonly used for passive components. The 0603 package sizewas subsequently replaced by a smaller 0402 package size having adimension of 40 mils in length and 20 mils in width, which wassupplanted by a 0201 package having a dimension of 20 mils in length by10 mils in width. Currently, the smallest package used for passivecomponents is a 01005 package having a dimension of 10 mils in length by5 mils in width. Because of their small size, soldering passivecomponents constructed using these packages to a PCB without a solderbridging problem or using insufficient solder is extremely difficult.Because of their small size it is also common for passives to fall offof an electronic assembly during the shipping and handling or field use.Using a pad construction with a needed passive component embedded in acontact pad using one or more conductive elastomers would allow use of asolderless assembly better suited for fine pitch assembly of electronicdevices.

While particular embodiments and applications of the present inventionhave been illustrated and described herein, it is to be understood thatthe invention is not limited to the precise construction and componentsdisclosed herein and that various modifications, changes, and variationsmay be made in the arrangement, operation, and details of the methodsand apparatuses of the present invention without departing from thespirit and scope of the invention as it is defined in the appendedclaims.

1. A method for assembling an electronic device, the method comprisessteps of: providing a substrate including a plurality of contactregions; providing a plurality of conductive elastomers having one ormore resistances; and coupling one or more conductive elastomers to acontact region included at the substrate, wherein the coupling embedsone or more passive components to the contact region.
 2. The method ofclaim 1, wherein resistances comprising at least one of: a resistanceassociated with an insulator, a resistance associated with asemiconductor, a resistance associated with a conductive resistor, or aresistance associated with a conductor.
 3. The method of claim 1 whereinthe substrate comprises at least one of: a bare integrated circuit die,a stacked integrated circuit die, a packaged integrated circuit, apackaged component, a stacked component, a flex circuit, a rigid flex,or a printed circuit board (PCB).
 4. The method of claim 1, wherein oneor more passive components comprises at least one of: a conductive padcoupled to the contact region included at the substrate, an insulatorpad coupled to the contact region included at the substrate, a resistor,a capacitor, a resistor coupled to a conducting path, a capacitorcoupled to a conducting path, a resistor coupled to a capacitor, aninductor coupled to a capacitor or an inductor coupled to a resistor. 5.A method for assembling an electronic device, comprising the steps of:manufacturing a substrate including a plurality of contact regions;coupling a first elastomer having a first resistance to a first contactregion included in the substrate; and coupling a second elastomer havinga second resistance to the first elastomer or to a second contact regionincluded in the substrate.
 6. The method of claim 5, wherein the firstresistance comprises at least one of: a resistance associated with aninsulator, a resistance associated with a semiconductor, a resistanceassociated with a conductive resistor or a resistance associated with aconductor.
 7. The method of claim 5, wherein the second resistancecomprises at least one of: a resistance associated with an insulator, aresistance associated with a semiconductor, a resistance associated witha conductive resistor or a resistance associated with a conductor. 8.The method of claim 5, wherein the first resistance comprises aresistance associated with an insulator and the second resistancecomprises a resistance associated with a conductor.
 9. The method ofclaim 5, wherein the step of coupling the second elastomer to the firstelastomer comprises: attaching a first surface of the first elastomer toa first surface of the second elastomer.
 10. The method of claim 5,wherein the step of coupling the second elastomer to the first elastomercomprises: attaching a first surface of the second elastomer to aperimeter of the first elastomer.
 11. The method of claim 10, furthercomprising the step of; attaching a third elastomer having a resistanceassociated with a conductor to a perimeter of the second elastomer. 12.The method of claim 5, wherein the first elastomer has a cross-sectionalgeometry comprises at least one of: a circular cross-section, atriangular cross-section, a square cross-section, a rectangularcross-section, a rhomboidal cross-section, an octagonal cross-section ora hexagonal cross-section.
 13. The method of claim 5, wherein the firstelastomer having the first resistance coupling to the first contactregion comprising a first contact pad of the electronic device; and thesecond elastomer having the second resistance coupling to the secondcontact region comprising a second contact pad of the electronic device.14. The first elastomer and the second elastomer of claim 5 are coupledby coupling the first contact region and the second contact regionincluded in the substrate.
 15. The electronic device of claim 5 furthercoupling to a target platform, wherein the target platform comprising aplurality of target contact regions and interconnects; coupling at leastone of the first elastomer or the second elastomer to a target contactregion included on the target platform.
 16. The target contact region ofclaim 15 further comprising a first contact region and a second contactregion.
 17. Associated with the target contact region of claim 16:coupling the first elastomer to the first contact region; and couplingthe second elastomer to the second contact region.
 18. The firstelastomer and the second elastomer of claim 17 are coupled by couplingthe first contact region and the second contact region included at thetarget platform.
 19. The target platform of claim 15, comprising atleast one of a bare integrated circuit die, a stacked integrated circuitdie, a packaged integrated circuit, a packaged component, a stackedcomponent, a flex circuit, a rigid flex, a printed circuit board (PCB)or a laminar of an anisotropic conductive elastomer.
 20. An interconnectof claim 15 comprising a connection to at least one of an electricalsignal, power, or ground connecting to the target contact region at thetarget platform.
 21. The electronic device of claim 15 couplingelectrical connection to the target contact region on the targetplatform mechanically.
 22. An electronic device for connection to atarget platform, the electronic device comprising: a pad contact; and aconductive elastomer having a resistance coupled to the pad contact, theconductive elastomer implementing one or more passive components. 23.The electronic device of claim 22, wherein the resistance comprises atleast one of: a resistance associated with an insulator, a resistanceassociated with a resistor or a resistance associated with a conductor24. The electronic device of claim 22, further comprising: a secondconductive elastomer having a second resistance coupled to theconductive elastomer or to the pad contact.
 25. The electronic device ofclaim 24, wherein the second resistance comprises at least one of: aresistance associated with an insulator, a resistance associated with aresistor or a resistance associated with a conductor.
 26. The electronicdevice of claim 24, further comprising: a third conductive elastomerhaving a third resistance coupled to the second conductive elastomer.27. The electronic device of claim 24, wherein a first surface of theconductive elastomer is coupled to a first surface of the secondconductive elastomer.
 28. The electronic device of claim 24, wherein afirst surface of the second conductive elastomer is coupled to aperimeter of the conductive elastomer.
 29. The electronic device ofclaim 22, wherein the conductive elastomer has a cross-sectionalgeometry comprises at least one of: a circular cross-section, atriangular cross-section, a square cross-section, a rectangularcross-section, a rhomboidal cross-section, an octagonal cross-section ora hexagonal cross-section.
 30. The electronic device of claim 22,wherein the pad contact comprises a first contact region and a secondcontact region.